RSA 2003 File No. RSA-006 revision. 0 -7/08/03
Tables on Oil Analysis
All Rights Reserve Reserve - 2003
Prepare by : Rolly Angeles Technical Training
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RSA 2003
TABLE OF CONTENTS Table 1 : ISO 4406 Fluid Cleanliness Standard ………………………………….. 1 Table 2 : Fluid Cleanliness Standard for New Oil …………...…………………… 1 Table 3 : Sample Standard Base Cleanliness Target ……….…………………… 2 Table 4 : General Water Concentration Limit ……………….…………………….. 2 Table 5 : Engine Problems Analyzed Through Oil Analysis .…………………….. 3 Table 6 : Recommended Test for Different Applications …………………………. 3 Table 7 : Comparing Multi-grade oil properties ……………………………………. 4 Table 8 : Another ISO 4406 Fluid Target Cleanliness Std………………………… 5 Table 9 : Commonly Recommended Oil Sampling Frequencies ………………… 6 Table 10 : Common Elements Found On Oil………………………………………. 6 Table 11 : What Different Oil Analysis Test Will Detect ………………………….. 7 Table 12 : Limits On Oil Analysis Tests ……………………………………………. 7
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Oil Analysis Important Tables Table 1 : ISO 4406 :99 Fluid Cleanliness Standard
ISO 4406 CODE 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
Number of Particles From To 320,000 640,000 160,000 320,000 80,000 160,000 40,000 80,000 20,000 40,000 10,000 20,000 5,000 10,000 2,500 5,000 1,300 2,500 640 1,300 320 640 160 320 80 160 40 80 20 40 10 20 5 10 2.5 5 1.3 2.5 0.6 1.3 0.3 0.6
Table 2 : Fluid Cleanliness Standard Comparison for New Oil
Without By-Pass ISO 22/17 > 5 = 29263 ppm > 15 = 1112 ppm > 25 = 29 ppm > 50 = 0 ppm >100 = 0 ppm
Brand New Oil ISO 17/14 > 5 = 1292 ppm > 15 = 119 ppm > 25 = 19 ppm > 50 = 5 ppm >100 = 0 ppm
With By-Pass Filter ISO 13/10 > 5= > 15 = > 25 = > 50 = >100 =
55 15 3 0 0
ppm ppm ppm ppm ppm
Table 13
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Oil Analysis Important Tables Table 3 : Sample Standard Cleanliness Target for System Applications
ISO RATING
MACHINE / COMPONENT
• Roller Roller Bearings
16/14/12
• Journal Journal Bearings
17/15/12
• Industrial Industrial Gearboxes
17/15/12
• Mobile Mobile Gearboxes
17/16/13
• Diesel Diesel Engines
17/16/13
• Steam Steam Turbine
18/15/12
• Paper Paper Machine
19/16/13
• Servo-Valve Servo-Valve
13/12/10
• Proportional Proportional Valve
14/13/11
• Variable Variable Volume Pump
15/14/12
• Fixed Fixed Piston Pump
16/15/12
• Vane Vane Pump
16/15/12
• Gear Gear Pump
16/15/12
• Ball Ball Bearing
14/13/11
• Turbine Turbine
17/15/12
Table 4 : General Water Concentration Limits
H20 Concentration
Action
Status
• 100 - 300
• Alert
• Check seals, breathers, coolers, etc., for ingression sources, watch the trend
• 300 - 800
• Danger
• Aggressively investigate and correct the source of ingression and implement an effective water removal activities
• 800 above
• Extremely Danger
• Immediate action is required to eliminate ingression and effect removal of water to minimize damage to machine and lubricant
Note : Unit of Water concentration in PPM
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Oil Analysis Important Tables Table 5 : Engine Problems Analyzed through Oil Analysis
Metal Traces
Limit
Engine Problem
What to Check • Air intake system • Oil filter plugging • Oil filler cap and breather • Valve cover
• Silicon
• 10 - 30 ppm
• Dirt Ingression
• Iron (Fe)
• 100 - 200 ppm
• Wear of cylinder liner • Valve and fear train • Oil pump • Rust in the system
• Excessive oil consumption • Abnormal engine noise • Performance problem • Oil pressure • Stuck or broken piston
• Chromium (Cr)
• 10 - 30 ppm
• Piston ring wear
• Excessive oil blow-by • Oil consumption / degradation
• Copper (Cu)
• 10 - 50 ppm
• Bearing / bushing wear • Radiator corrosion
• Coolant in engine oil • Abnormal noise on operating at stall speed
• Lead (Pb)
• 40 - 100 ppm
• Bearing corrosion
• Extended oil change intervals
• Aluminum (Al)
• 10 - 30 ppm
• Piston and piston thrust • Bearing wear
• Blow-by gases • Oil consumption • Power loss • Abnormal engine noise
Table 6 : Recommended Test for different applications
Equipment Engines Compressor Gearboxes Bearings Hydraulics Turbines Motor Where :
Spectro Analysis
Viscosity
FTIR
Particle Count
Karl Fisher
TAN
TBN
Rotrode Filter
R R R R R R R
R R R R R R R
R R R R R R R
---A ---A R R ----
R R ------A R ----
R ---------A R ----
R -------------------
A R R R R R R
R - Require Test A - Advisable, provides extra details
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RSA 2003 Table 7 : Comparing Multi-grade Oil Properties
BRAND (SAE 20W-50) AMSOIL Castrol GTX Exxon High Perfmance Havoline Formula 3 Kendall GT-1 Pennzoil GT Performance Quaker State Dix Red Line Shell Truck Guard Spectro Golden 4 Spectro Golden M.G. Unocal Valvoline All Climate Valvoline Turbo Valvoline Race Valvoline Synthetic
BRAND (SAE 20W-40) Castrol Multi-Grade Quaker State Dix
BRAND (SAE 15W-50) Chevron Mobile 1 Mystic JTS Red Line
BRAND (SAE 5W-50) Castrol Syntec Quaker State Sunquest Pennzoil Performax
BRAND (SAE 5W-40) Havoline
BRAND (SAE 15W-40) AMSOIL Castrol Chevron Delo 400 Exxsn XD3 Exxon XD3 Extra Kendall GT-1 Mystic JT8 Red Line Shell Rotella w/ XLA Valvoline all fleet Valvoline Turbo
BRAND (SAE 5W-30) AMSOIL Castrol GTX Chevron Supreme Chevron Supreme Synthetic Exxon Superflow HP Havoline Formula 3
VI
Flash
Pour
% Ash
% Zinc
136 122 119 125 129 120 155 150 130 174 174 121 125 140 140 146
482 440 419 465 390 460 430 503 450 440 440 432 430 440 425 465
-38 -15 -13 30 -25 -10 -25 -49 -15 -35 -35 -11 -10 -10 -10 -40
< 0.50 0.85 0.70 1.00 1.00 0.90 0.90 --1.00 ----0.74 1.00 0.99 1.20 <1.50
--0.12 0.11 --0.16 ------0.15 0.15 0.13 0.12 0.11 0.13 0.2 0.12
VI
Flash
Pour
% Ash
% Zinc
110 121
440 415
-15 -15
0.85 0.90
0.12 ---
VI
Flash
Pour
% Ash
% Zinc
204 170 144 152
415 470 420 503
-18 -55 -20 -49
0.96 --1.70 ---
0.11 --0.15 ---
VI
Flash
Pour
% Ash
% Zinc
180 173 176
437 457 ---
-45 -76 -69
1.20 -----
0.1 -----
VI
Flash
Pour
% Ash
% Zinc
170
450
-40
1.40
---
VI
Flash
Pour
% Ash
% Zinc
135 134 136 --135 135 142 149 146 140 140
460 415 421 417 399 410 440 495 410 --420
-38 -15 -27 -11 -11 -25 -20 -40 -25 -10 -10
<0.50 1.30 1 0.9 0.95 1 1.7 --1 1 0.99
--0.14 --0.14 0.13 0.16 0.15 --0.13 0.15 0.13
VI
Flash
Pour
% Ash
% Zinc
168 156 202 165 148 158
480 400 354 446 392 420
-76 -35 -46 -72 -22 -40
<0.50 0.8 0.96 1.1 0.7 1
--0.12 0.11 0.12 0.11 ---
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Oil Analysis Important Tables Table 8 : Guidelines for determining, achieving and maintenance Target Cleanliness Levels with High Performance Filtration (Beta Ration > 200)
Most Sensitive System Components
Low
Medium
High
Pressure
Pressure
Pressure
140 Bar
140 - 210 Bar
210 Bar - up
ISO Target
Micron
ISO Target
Micron
ISO Target
Micron
Levels
Rating
Levels
Rating
Levels
Rating
10 10 6 3
20/16/14 19/16/13 19/15/12 18/14/12
10 6 3 3
10 10 10 6 3 3
20/16/14 20/16/14 20/16/14 19/15/12 17/13/11 16/12/10
10 10 10 3 3 3
16 16 6 6 3
19/16/13 19/16/13 19/15/12 19/15/12 17/13/11
6 6 3 3 3
n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
PUMPS Fixed External Gears Vane Pump Fixed Piston Variable Piston
21/17/14 21/17/14 20/16/14 19/16/13
25 25 10 6
20/16/14 20/16/14 19/16/13 19/15/12
VALVES Check Valves Directional (Solenoid) Standard Flow Control Cartridge Valve Proportional Valve Servo Valve
21/17/14 21/17/14 21/17/14 20/16/14 19/15/12 18/14/12
25 25 25 10 3 3
20/16/14 20/16/14 20/16/14 19/16/13 18/14/12 17/13/11
ACTUATORS Cylinders , Vane Motors Gear Motors Pis ton Motors Swash Plate Motors Hydrostatic Drives
22/18/15 22/18/15 20/16/14 20/16/14 19/15/12
25 25 10 10 3
20/17/14 20/17/14 19/16/13 19/16/13 18/14/12
LUBRICATING OILS Paper Machine Oils Steam Turbin Oils Diesel Engines Mobile Gear Box Industrial Gear Box Journal Bearings Roller Bearings Ball Gearings
21/16/13 20/15/12 19/16/13 19/16/13 19/15/12 19/15/12 18/14/12 17/13/11
n.a. n.a. n.a. n.a. n.a. n.a. n.a. n.a.
3 3 3 3 3 3 3 3
• Severe conditions may include high flow surges, pressure spikes, frequent cold starts, extremely heavy duty use or the presence of water • Two or more systems filters of the recommended rating may be re quired to achieve and maintain the desired Target Cleanliness Level (ISO 4406 : 99)
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Oil Analysis Important Tables Table 9 : Commonly Recommended Oil Sampling Frequencies
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Machine Type
Hours
Diesel Engine Transmission, differentials, final drives Hydraulics - Mobile Equipments Gas Turbines - industrial Steam Turbines Air / Gas Compressors Chillers Gear boxes - high speed / duty Gear boxes - low speed / duty Bearings - journal and rolling elements Aviation reciprocating engines Aviation gas turbines Aviation gear boxes Aviation hydraulics
150 300 200 500 500 500 500 500 300 1000 25 - 50 100 100 - 200 100 - 200
Table 10 : Commonly Elements Found On Oil
Item 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16
Element Iron Copper Chromium Tin Aluminum Lead Silicon Sodium Boron Calcium Magnesium Zinc Phosporous Molybdenum Potassium
Symbol (Fe) (Cu) (Cr) (Sn) (Al) (Pb) (Si) (Na) (B) (Ca) (Mg) (Zn) (P) (Mo) (K)
Wear x x x x x x
Contam x x
Additive x
x x x x x x
x x
x x x x x x x x
x
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Oil Analysis Important Tables Table 11 : What Different Oil Analysis Test Will Detect
LUBE MACHINE CONDITION
OIL ANALYSIS Test
Particle Count
n o i t a n i m a t n o C e l c i t r a P
n o i t c e t e D i r b e D r a e W
s i s y l a n A i r b e D r a e W
P
S
S
Viscosity
P S S
TAN / TBN FTIR Spect roscopy Ferrous Density Analytic al Ferrography
y t i s o c s i V l a m r o n b A
P S
n o i t a n i m a t n o C e r u t s i o M
n o i t e l p e D e v i t i d d A
y t i l i b a t S n o i t a d i x O
S P
S P P
S P
d a o L t o o S
S
S
S
S
P
l i O g n o r W
P
P S P
P
P
Moisture Tester
S
P
P S
P
Flash Point Test
P = Primary Indicator
n o i t u l i D l e u F
e v r e s e R y t i n i l a k l A
e r u l i a F l a m r e h T
P S
P
S
P
S P
P S
S S P
S = Secondary Indicator
Oil Analysis Test
Caution
Critical
Shell Limits
Cleanliness Dryness TAN Fuel Glycol Soot Viscosity RPVOT FTIR (Ox) Zinc Calcium TBN Water
ISO 14/11 200 0.2 1.50% 200 ppm 2% +5% - 30 % 0.3 -15 % -10 - 50% 100 - 300 ppm
ISO 16/13 600 0.4 5% 400 ppm 5% + 10% - 60 % 1 - 30 % 20% - 75 % above 300 ppm
no data no data no data no data no data no data +/- 20 % no data no data no data no data 2 mg KOH min 0.10% by vol.
Metals - Silicon (Si) - Chromium (Cr) - Lead (Pb) - Aluminum (Al) - Copper (Cu)
100- 200 ppm 10 - 30 ppm 10 - 30 ppm 40 - 100 ppm 10 - 30 ppm 10 - 50 ppm
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P S
S
Table 12 : Limits On Oil Analysis Tests
- Iron (Fe)
n o i t i d n o C e v i s o r r o C
S P
RPVOT Elemental Spectroscopy
n o i t a n i m a t n o C l o c y l G
Shell Limits above 200 ppm above 30 ppm above 30 ppm above 100 ppm above 30 ppm above 50 ppm
3 - 150 ppm 1 - 15 ppm 0 - 20 ppm 3 - 50 ppm 2 - 20 ppm - 5 - 65 ppm Rolly Angeles